Process for the Rapid Blackening of Surgical Needles

ABSTRACT

A novel method of blackening surgical needles is disclosed. Surgical needles having outer surfaces are first placed into a first pretreatment bath having a novel composition. The needles are then placed into a second blackening bath having a novel composition for a sufficient period of time to effectively blacken the surfaces of the needles. The novel methods for blackening the surfaces of a stainless steel alloy surgical needle provide a chromium (VI)-free alternative to current needle manufacturing processes. Another unique feature of this novel method is its short processing time. The blackening processes of the present invention can be utilized for in-line treatment processes which can be easily incorporated into high speed needle manufacturing processes, such as strip mounted processes. In addition, the processes of the present invention are readily adaptable to batch processes. Also disclosed are novel systems for blackening surgical needles and novel blackening baths for surgical needles.

FIELD OF THE INVENTION

The field of art to which this invention pertains is manufacturingprocesses for surgical needles, more particularly, processes forblackening the surfaces of surgical needles.

BACKGROUND OF THE INVENTION

Surgical needles are typically made from conventional metals such assurgical stainless steels and other biocompatible metal alloys. Theneedles desirably have smooth outer surfaces to facilitate the passagethrough tissue and minimize the adherence of contaminants or foreignsubstances. The needle surfaces are typically polished to provide smoothsurfaces that are bright, shiny and reflective. Surgical needles aretypically coated with silicone coatings to improve the penetration ofthe needles through multiple passes in tissue.

In certain types of surgical procedures such as endoscopic andlaparoscopic surgical procedures, the surgeon views the site of theprocedure remotely via a camera and a screen display of the surgicalfield. It is known that in such procedures the surgical team may havedifficulty in seeing a conventional surgical needle because of the shinyreflective surfaces. This is particularly true of the distal end of theneedle having the tissue piercing point. The inability to quickly andefficiently locate the needle and needle tip when conducting alaparoscopic suturing procedure has led to the development of surgicalneedles having blackened surfaces. The blackened needles have proven tohave better visibility in the surgical field and are often preferred inminimally invasive surgical procedures utilizing indirect visualization.

Blackening processes for blackening the bright, shiny surfaces ofsurgical needles are known in this art. The processes may includechemical baths, exposure to plasmas, laser energy, oxidizing fumes, etc.The objective of the blackening processes is to form an iron oxide(Fe₂O₄)-based layer on the surfaces of the stainless steel needles whichprovides the blackened appearance.

The chemical baths used in the prior art processes typically containChromium (VI) as a component of the baths. Such processes are oftenlengthy and typically require process times in excess of twenty hours toprovide effectively blackened surfaces on the needles.

Although the chemical needle blackening processes of the prior art areeffective in providing blackened surfaces on surgical needles, there areknown deficiencies associated with their use. First of all, the use ofblackening baths containing the requisite high concentrations ofChromium (VI) compounds presents both environmental risks and safetyhazards. The safety hazards include the carcinogenicity of the Chromium(VI) compounds. Chronic inhalation of hexavalent chromium compounds isknown to increase the risk of lung cancer. (The lungs are the mostvulnerable, followed by the fine capillaries in kidneys and intestines).Soluble Chromium (VI) compounds in conventional needle blackeningsolutions can cause or exacerbate contact dermatitis. Ingestion ofchromium VI can also cause irritation or ulcers in the stomach andintestines. The environmental risks associated with Chromium(VI)-containing blackening baths include ground water and soilcontamination, which leads to the risk of exposure to humans, domesticand farm animals, and wildlife. In addition to the safety hazards andenvironmental risks associated with such processes, it is known that theexisting processes are extremely slow, typically requiring process timesin excess of 20 hours up to 36 hours in order to achieve sufficientlyeffective blackening. This necessitates that such blackening processesare batch-type processes in which larger batches of needles are immersedin the blackening baths. The conventional processes cannot be used withhigh speed needle manufacturing processes wherein needles are mounted tostrips and moved at a relatively high rate of speed to and from variousmanufacturing steps. Finally, the existing processes are not costeffective for a variety of reasons including production efficiency,generation and disposal of hazardous waste, burdensome engineeringcontrols, substantial safety requirements, potential liability, etc.

Accordingly, there is a need in this art for novel methods and processesfor blackening surgical needles that eliminate the need for Chromium(VI) compounds in blackening baths. There is a further need forblackening methods and processes that provide quick process times, areenvironmentally friendly, safe to operate, and are cost effective.

SUMMARY OF THE INVENTION

Therefore a novel method of blackening the surfaces of surgical needlesis disclosed. In the novel method of the present invention, at least onesurgical needle having an outer surface is placed into a pretreatmentbath. The pretreatment bath contains about 8 wt. % to about 20 wt. % ofa water soluble chloride salt, about 5 wt. % to about 15 wt. % of aninorganic acid, and about 60 wt. % to about 90 wt. % of water. Thepretreatment bath has a pH of about 0.5 to about 1.2. The surgicalneedle is then placed into a blackening bath. The blackening bathcontains about 3 wt. % to about 20 wt. % of a highly soluble nitric acidsalt, about 18 wt. % to about 38 wt. % of a strong base, about 50 wt. %to about 75 wt. % of water, about 0.2 wt. % to about 5 wt. % of atransition metal salt of a strong acid, and about 0.2 wt. % to about 5wt. % of a sulfur-containing reducer compound. The needle is maintainedin the bath for a sufficiently effective period of time to provide ablackened coating on the outer surfaces of the needle.

Another aspect of the present invention is a novel method of blackeningthe surfaces of surgical needles. In the novel method of the presentinvention, at least one surgical needle having an outer surface isplaced into a pretreatment bath. The pretreatment bath contains about 8wt. % to about 20 wt. % of a water soluble chloride salt, about 5 wt. %to about 15 wt. % of an inorganic acid, and about 60 wt. % to about 90wt. % of water. The pretreatment bath has a pH of about 0.5 to about1.2. The surgical needle is then placed into a blackening bath. Theblackening bath contains about 3 wt. % to about 20 wt. % of a highlysoluble nitric acid salt, about 18 wt. % to about 38 wt. % of a strongbase, about 50 wt. % to about 75 wt. % of water, about 0.2 wt. % toabout 5 wt. % of a highly soluble permanganate salt, and about 0.2 wt. %to about 5 wt. % of a thiocyanate salt. The needle is maintained in thebath for a sufficiently effective period of time to provide a blackenedcoating on the outer surfaces of the needle.

Yet another aspect of the present invention is a novel composition foruse as a needle blackening bath. The composition contains about 3 wt. %to about 20 wt. % of a highly soluble nitric acid salt, about 18 wt. %to about 38 wt. % of a strong base, about 50 wt. % to about 75 wt. % ofwater, about 0.2 wt. % to about 5 wt. % of a transition metal salt of astrong acid, and about 0.2 wt. % to about 5 wt. % of a sulfur-containingreducer compound.

Still yet another aspect of the present invention is a novel compositionfor use as a needle blackening bath. The composition contains about 3wt. % to about 20 wt. % of a highly soluble nitric acid salt, about 18wt. % to about 38 wt. % of a strong base, about 50 wt. % to about 75 wt.%

of water, about 0.2 wt. % to about 5 wt. % of a highly solublepermanganate salt, and about 0.2 wt. % to about 5 wt. % of a thiocyanatesalt.

An additional aspect of the present invention is a system for blackeningstainless steel alloy surgical needles. The system has a pretreatmentbath and a blackening bath. The pretreatment bath contains about 8 wt. %to about 20 wt. % of a water soluble chloride salt, about 5 wt. % toabout 15 wt. % of an inorganic acid, and about 60 wt. % to about 90 wt.% of water. The pretreatment bath has a pH of about 0.5 to about 1.2.The blackening bath contains about 3 wt. % to about 15 wt. % of a highlysoluble nitric acid salt, about 18 wt. % to about 38 wt. % of a strongbase, about 50 wt. % to about 75 wt. % of water, about 0.2 wt. % toabout 5 wt. % of a transition metal salt of a strong acid, and about 0.2wt. % to about 5 wt. % of a sulfur-containing reducer compound.

A further aspect of the present invention is a system for blackeningstainless steel alloy surgical needles. The system has a pretreatmentbath and a blackening bath. The pretreatment bath contains about 8 wt. %to about 20 wt. % of a water soluble chloride salt, about 5 wt. % toabout 15 wt. % of an inorganic acid, and about 60 wt. % to about 90 wt.% of water. The pretreatment bath has a pH of about 0.5 to about 1.2.The blackening bath contains about 3 wt. % to about 20 wt. % of a highlysoluble nitric acid salt, about 18 wt. % to about 38 wt. % of a strongbase, about 50 wt. % to about 75 wt. % of water, about 0.2 wt. % toabout 5 wt. % of a highly soluble permanganate salt, and about 0.2 wt. %to about 5 wt. % of a thiocyanate salt.

These and other aspects and advantages of the present invention willbecome more apparent from the following description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a photograph showing a side perspective view of a rotationalbasket useful in the practice of the present invention; a magnetic baris mounted to the interior bottom of the basket.

FIG. 2 is a photograph of a top perspective view of the basket of FIG. 1showing a magnetic bar mounted to the bottom of the basket.

FIG. 3A is a photograph of needles blackened using the processes of thepresent invention (Example 6) wherein the processing time was 2 minutesto completion.

FIG. 3B is a photograph of needles identical to the needles of FIG. 3A,but treated using a blackening process of the prior art (Example 15)wherein the processing time was also 2 minutes; virtually no blackeningof the surfaces of the needles can be observed.

FIG. 4 is a graph showing the difference in process time between theprocess of the present invention described in Example 5 and aconventional Chromium (VI)-based process.

FIG. 5 is a graph showing Auger surface analysis of Example 5.

DETAILED DESCRIPTION OF THE INVENTION

The surgical needles that can be blackened using the novel process ofthe present invention will include conventional surgical needles havingconventional shapes made from conventional surgical grade stainlesssteel alloys. The stainless steel alloys will include but not be limitedto Type 455, Type 316, Type 4310, Type 420, and the like. Another typeof stainless steel alloy that can be blackened using the processes ofthe present invention is the proprietary alloy “ETHALLOY” available fromEthicon, Inc., Somerville, N.J. 08876 USA. The composition of ETHALLOYalloy is described in U.S. Pat. No. 5,000,912, which is incorporated byreference. The processes, baths and systems of the present invention canalso be used to blacken the surfaces of other types of medical devices,in addition to needles, made from such alloys.

The processing equipment useful in the practice of the present inventionwill include conventional processing equipment such open vats, tanks,mixing apparatus, and baskets. The equipment may include speciallydesigned and adapted tanks for receiving needles on strips when usinghigh speed needle manufacturing processes. The equipment will be made ofconventional corrosion resistant materials such as Nylon, glass, PEEK,Teflon, PVDF, and the like. The equipment may be made of conventionalmetals such as aluminum, and stainless steel that have had their contactsurfaces coated with conventional corrosion resistant coatings such asceramic, PTFE, FEP, and the like.

The baths used in the pretreatment step of the process of the presentinvention will be aqueous-based compositions. The pretreatment bathswill have sufficient quantities of the bath ingredients to provide foreffective pretreatment. The pretreatment baths will typically containabout 8 wt. % to about 20 wt. % of a water soluble chloride salt, moretypically about 10 wt. % to about 18 wt. %, and preferably about 15 wt.% to about 17 wt. %. The pretreatment baths will also contain about 5wt. % to about 15 wt. % of an inorganic acid, more typically about 6 wt.% to about 10 wt. %, and preferably about 7 wt. % to about 8 wt. %. And,the pretreatment baths will typically contain about 60 wt. % to about 90wt. % of water, more typically about 70 wt. % to about 80 wt. %, andpreferably about 75 wt. % to about 78 wt. %. The water soluble chloridesalts useful in the pretreatment baths include but are not limited tosodium chloride, potassium chloride, lithium chloride and the like. Theinorganic acids useful in the pretreatment baths include but are notlimited to phosphoric acid, sulfuric acid, hydrochloric acid, nitricacid, and the like. The pH of the pretreatment baths will typicallyrange from about 0.1 to about 1.2, more typically about 0.3 to about 1,and preferably about 0.5 to about 0.8.

The blackening bath compositions useful in the blackening processes ofthe present invention will be aqueous-based compositions. The blackeningbaths will have sufficient quantities of the bath ingredients to providefor effective blackening of the surfaces of needles. The blackeningbaths will typically contain about 18 wt. % to about 38 wt. % of astrong base, more typically about 20 wt. % to about 35 wt. %, andpreferably about 26 wt. % to about 30 wt. %. The blackening baths of thepresent invention will typically contain about 3 wt. % to about 20 wt. %

of a highly soluble nitric acid salt, more typically about 5 wt. % toabout 15 wt. %, and preferably about 11 wt. % to about 13 wt. %. And theblackening baths will typically contain about 50 wt. % to about 75 wt. %of water, more typically about 55 wt. % to about 70 wt. %, andpreferably about 58 wt. % to about 65 wt. %. The nitric acid saltsuseful in the blackening baths of the present invention include but arenot limited to sodium nitrate, potassium nitrate, lithium nitrate, andthe like. The strong bases useful in the blackening baths of the presentinvention include but are not limited to sodium hydroxide, potassiumhydroxide, lithium hydroxide, and the like.

In a first embodiment, the blackening baths of the present inventionwill also contain components containing two different precursors to formtransition metal sulfides. The first precursor is a transition metalsalt of a strong acid. Such precursors include but are not limited tonickel nitrate, cobalt nitrate, nickel sulphate, cobalt sulphate, ironnitrate, copper perchlorate, nickel perchlorate, ion perchlorate, andcobalt perchlorate and the like. The second precursor is asulfur-containing reducer. Such second precursors include but are notlimited to N,N′-diethylthiourea, sodium thiocyanate, sodium sulfide, andsodium dimethyldithiocarbamate and the like. The transition metalsulfide compounds that are formed may include, but are not limited to,NiS, CoS, Ag₂S, etc. The amount of the transition metal salt of a strongacid included in this embodiment of the blackening baths of the presentinvention is typically about 0.1 wt. % to about 3 wt. %, more typicallyabout 0.2 wt. % to about 2 wt. %, and preferably about 0.3 wt. % toabout 1 wt. %. The amount of the sulfur-containing reducer included inthis embodiment of the blackening baths of the present invention istypically about 0.1 wt. % to about 3 wt. %, more typically about 0.2 wt.% to about 2 wt. %, and preferably about 0.3 wt. % to about 1 wt. %.

In a second embodiment, the blackening baths of the present inventionwill also contain manganese-containing oxidizers, also referred to ashighly soluble permanganate salts, including but not limited topotassium permanganate, sodium permanganate, and lithium permanganate,and the like. The baths in the second embodiment will also contain athiocyanate salt. The thiocyanate salts useful in this embodiment of theblackening baths include but are not limited to as sodium thiocyanate,potassium thiocyanate, lithium thiocyanate, and the like. The amount ofthe manganese-containing oxidizer (highly soluble permanganate salt) inthis second embodiment of the blackening baths of the present inventionis typically about 0.1 wt. % to about 5 wt. %, more typically about 0.2wt. % to about 3 wt. %, and preferably about 0.3 wt. % to about 1 wt. %.The amount of the thiocyanate salt included in this embodiment of theblackening baths of the present invention is typically about 0.1 wt. %to about 5 wt. %, more typically about 0.2 wt. % to about 3 wt. %, andpreferably about 0.3 wt. % to about 1 wt. %.

The second embodiment of the blackening baths may optionally includeseveral additives to enhance the color of the black oxide layer, andenable the repeat usage of the blackening bath. The additives includeand are not limited to 1. molybdate salts including ammonium molybdate,sodium molybdate and potassium molybdate; and, 2. sodium chloride. Theamount of molybdate salts optionally present in this embodiment will besufficient to provide effective blackening enhancement and wouldtypically range from 0.1 wt. % to about 3 wt. %. The amount of sodiumchloride optionally present in this embodiment will be sufficient toprovide effective blackening enhancement and would typically range from0.3 wt. % to about 1 wt. %.

The pretreatment bath compositions and the blackening bath compositionsmay be made in a conventional manner using conventional process andmixing equipment. For example, the blackening and pretreatment bathcompositions may be made in the following manner: mixing all of thecomponents using a mechanical mixer for a sufficiently effective time upto about one hour until all of the solid components are fully dissolvedin the aqueous solution.

The novel methods of the present invention for blackening surgicalneedles consist of two primary steps. The initial step is a pretreatmentstep that is performed prior to the needle blackening step. In thepretreatment step surface oxides are removed from the surfaces of theneedles. The second step is the needle blackening step. In theblackening step, a black oxide coating is formed on the surfaces of theneedles.

The pretreatment step is directed toward the removal of surface oxides.Stainless steels are covered with a layer of chromium oxide which makesthem corrosion resistant. This oxide layer results in the surface beingpassivated and resists further chemical treatment. The activatingsolution reacts with chromium oxide and enables the surfaces of thestainless steel needles to be chemically receptive to the variousblackening solutions utilized in the second blackening step. Any surfacecontaminants present on the needles surfaces such as machine oil andgrease will also be removed during this step. Various acids such ashydrochloric acid, phosphoric acid and sulfuric acid are commonly usedat elevated temperature for this purpose.

Therefore, the first step is also referred to as a pickling process stepwhich typically lasts about 10 minutes to about one hour. Theformulation for a pretreatment bath listed below in Table 1 wasdeveloped for a 30 second activation process adapted to an in-lineprocess and 3 minutes for a large scale batch process. The processtemperature for this bath formulation is 80° C., well below the boilingpoint of the solution to prevent fume formation of hazardous material.

In the pretreatment process, a pretreatment bath solution as describedabove and in the Tables and Examples is prepared using conventionalmixing equipment and process equipment. The solution is transferred to aconventional bath vessel having the desired dimensions and volumetriccapacity. The pretreatment process step can be conducted as a batchprocess or a continuous process. It will be appreciated that the bathconfiguration will also depend on whether the pretreatment process isbatch or continuous. In a batch process, the needles are typicallyloaded into a basket and immersed in the bath in the bath solution. Theneedles are maintained in the bath for a sufficient period of time at asufficient temperature to effectively pretreat the surfaces of theneedles. The time will typically range from about 30 seconds to about 1hour, more typically about 1 minute to about 30 minutes, and preferablyabout 2 minutes to about 5 minutes, depending upon on the amount ofneedles in the batch. The temperature of the pretreatment bath willtypically range from about 60° C. to about 100° C., more typically about70° C. to about 90° C., and preferably about 75° C. to about 85° C.

In a continuous process, needles are typically mounted to a strip forrapid movement between manufacturing stations in a high speed needleoperation. In such a process, the strip mounted needles are movedthrough the pretreatment bath while mounted to the strip. The needlesare maintained in the bath for a sufficient period of time at asufficient temperature to effectively pretreat the surfaces of theneedles. The time will typically range from about 20 seconds to about 60seconds, more typically about 25 seconds to about 45 seconds, andpreferably about 30 seconds to about 40 seconds. The temperature of thepretreatment bath will typically range from about 60° C. to about 100°C., more typically about 70° C. to about 80° C., and preferably about75° C. to about 85° C.

The blackening process is performed in a similar manner to thepretreatment process. In the blackening process, a blackening bathsolution as described above is prepared using conventional mixingequipment and process equipment. The solution is transferred to aconventional bath vessel having the desired dimensions and volumetriccapacity. The blackening process step can be conducted as a batchprocess or a continuous process. It will be appreciated that the bathconfiguration will also depend on whether the blackening process isbatch or continuous. In either case, the bath may be optionally agitatedby conventional equipment. In a batch process, the needles are typicallyloaded into a basket and immersed in the bath in the bath solution. Thequantity of needles in a batch will vary with the size of the system,and may range for example from less than 10 to more than 10,000 needles.The needles are maintained in the bath for a sufficient period of timeat a sufficient temperature to effectively treat the surfaces of theneedles to obtain blackened surfaces. The time will typically range fromabout 1 minute to about 60 minutes, more typically about 2 minutes toabout 30 minutes, and preferably about 2 minutes to about 4 minutes. Thetemperature of the blackening treatment bath will typically range fromabout 90° C. to about 140° C., more typically about 95° C. to about 110°C., and preferably about 98° C. to about 105° C. In a continuousprocess, needles are typically mounted to a strip for rapid movementbetween manufacturing stations in a high speed needle operation. In sucha process, the strip mounted needles are moved through the blackeningbath while mounted to the strip. The needles are maintained in the bathfor a sufficient period of time at a sufficient temperature toeffectively blacken the surfaces of the needles. The typical number ofneedles in the treatment bath may range, for example, from 20 or less to100 or more needles at one time. The treatment time will typically rangefrom about 5 seconds to about 40 seconds more typically about 10 secondsto about 30 seconds, and preferably about 15 seconds to about 25seconds. The temperature of the blackening treatment bath will typicallyrange from about 90° C. to about 140° C., more typically about 95° C. toabout 110° C., and preferably about 98° C. to about 105° C.

Unlike the acid/Cr(VI)-based processes currently used in this art, thenovel processes of the present invention are alkali-based processes thatprovide for and enable the rapid formation of black oxide on the surfaceof stainless steel surgical needles. The activated stainless steelneedles are immersed into an aqueous alkaline solution consisting ofsodium hydroxide, sodium nitrate and several other minor components (thebasic composition of the blackening solution is outlined in Table 2, theweight % of each minor component is typically less than 0.5) at anelevated temperature below its boiling point, which is different fromother conventional and commercial blackening processes. Thissubstantially reduces or eliminates toxic fume formation during theblackening process step. Using the novel process of the presentinventions, it has been observed, surprisingly and unexpectedly, thatsmall batches of needles (under 50 units) are blackened within 30seconds (can be as short as 10 seconds), and large batches of needles(up to several thousand or more) are blackened after 2 minutes immersionin the novel blackening bath solutions of the present invention. Theprocess temperature is 100° C., well below the boiling point of thesolution to substantially reduce or eliminated the formation of fumescontaining hazardous materials.

Similar to the prior art Cr(VI) based blackening process, in which theblack oxide (Fe₃O₄) layer is formed alongside the formation of Cr₂O₃,the formation of a second ceramic material is needed to start to ironoxide formation in the novel blackening process of the presentinvention. The minor components in the formulation are the precursorsfor the second phase ceramic material. Typically two different types ofminor components are used in the formulation:

Type 1 components containing two different precursors to form transitionmetal sulfide.

1. Transition metal salt of strong acid, such as nickel nitrate, cobaltnitrate, nickel sulfate, cobalt sulfate, iron nitrate, copperperchlorate, nickel perchlorate, ion perchlorate, cobalt or perchlorate;and,

2. Sulfur-containing reducer compounds, such as N,N′-diethylthiourea,sodium thiocyanate, sodium sulphide, sodium dimethyldithiocarbamate.

Transition metal sulfides will form on the surface of stainless steel asthe result of the blackening process with Type 1 components.

Type 2 components containing manganese-containing oxidizers such aspotassium permanganate, and several additives as previously described toenhance the color of the black oxide layer, and enable the repeatedusage of the blackening baths.

Manganese oxides will form on the surface of stainless steel as a resultof the blackening process with Type 2 components.

A stabilizer may also be used in the blackening bath formulations of thepresent invention to enable multiple usage and prolong the pot life ofthe blackening solution. An example of stabilizers for incorporation inthe blackening bath solution includes and is not limit to sodiumchloride, ammonium molybdate, sodium thiocyanate, and sodium cyanate.The blackening solution is capable of being used multiple times afterthe addition of a stabilizer compound. The color of the resultingblackened needles remains consistent between batches after repeat usageof the blackening solution. This provides the advantage of improvedproduction capability and minimizes the amounts of chemical wastegenerated from the blackening process.

In the following examples, a novel rotational basket 10 was used forboth steps of the needle blackening process. The structure of the basketis illustrated in FIGS. 1 and 2. High temperature plastic such as nylonor high density polypropylene (HDPP) was used to construct the frame 20of the basket 10. Nylon mesh 30 was used to cover the entire frame 20 ofbasket 10 to allow the chemical solutions used in both steps topenetrate through and react with the surface of thousands of needlescontained in a batch inside the basket. The rotating mechanism consistsof a magnetic bar 40 mounted on the bottom 12 of the mesh basket 10 asseen in FIG. 1. The mesh basket 10 is able to rotate at a controllablespeed on a conventional magnetic stirrer. This equipment allows asubstantial amount of needles (e.g., over 3,000 larger needles and over20,000 micro needles) to be blackened in a short period of time (e.g., 5minutes). The full and complete exposure of the entire batch of surgicalneedles to the blackening solution allows all of the surfaces of eachneedle to be converted to a black color (homogeneous colorization). Thegentle rotation provide by this basket prevents point damage that mayoccur and be caused by needle collisions during agitation.

The following examples are illustrative of the principles and practiceof the present invention, although not limited thereto:

TABLE 1 Composition of Activating Solution. Material Weight (%) SodiumChloride 16.7 Phosphoric Acid (85% in water) 9.0 Water 74.3

TABLE 2 Composition of Blackening Solution. Material Weight (%) Sodiumhydroxide 28 Sodium nitrate 12 Water 60

EXAMPLE 1 Formation of Nickel Sulfide-Containing Iron Oxide Black Layer

A small amount of transition metal salt (nickel nitrate) and sulfideprecursor (sodium sulfide) was added to an alkaline solution of sodiumnitrate as listed in Table 2 and the formulation of this blackeningsolution is listed in Table 3.

TABLE 3 Formulation of Blackening Solution Component Formula Weight (g)Sodium Nitrate NaNO₃ 15 Sodium Hydroxide NaOH 35 Water H₂O 75 Nickel(II)Nitrate Hexahydrate NiNO₃•6H₂O 1 Sodium Sulfide Nonahydrate Na₂S•9H₂O 3

A quantity of thirty (30) 22 mil type 4310 SH needles (manufactured byEthicon, Inc.) was immersed in a bath containing the activating solutionlisted in Table lat 80° C. for 2 minutes. The needles were then rinsedwith water and immersed into a bath containing the blackening solutionlisted in Table 3 at 100° C. for 1 minute. The surfaces of the silverneedles turned completely black.

EXAMPLE 2 Formation of Copper Sulfide-Containing Iron Oxide Black Layer

A small amount of transition metal salt (copper nitrate) and sulfideprecursor (sodium sulfide) was added to an alkaline solution of sodiumnitrate listed in Table 2 and the formulation of this blackeningsolution is summarized in Table 4.

TABLE 4 Formulation of Blackening Solution. Component Formula Weight (g)Sodium Nitrate NaNO₃ 15 Sodium Hydroxide NaOH 35 Water H₂O 75 Copper(II)Nitrate Trihydrate CuNO₃•3H₂O 1 Sodium Sulfide Nonahydrate Na₂S•9H₂O 3

A quantity of thirty (30) 22 mil type 4310 SH needles (manufactured byEthicon, Inc.) was immersed in a bath containing the activating solutionlisted in Table 1 at 80° C. for 2 minutes. The needles were removed andrinsed with water, and then immersed in a bath containing the blackeningsolution listed in Table 4 at 100° C. for 1 minute. The color of thesurfaces of the silver needles turned completely black.

EXAMPLE 3 Formation of Cobalt Sulfide-Containing an Iron Oxide BlackLayer

A small amount of transition metal salt (cobalt nitrate) and sulfideprecursor (sodium sulfide) was added to an alkaline solution of sodiumnitrate listed in Table 2. The formulation of this blackening solutionis summarized in Table 5.

TABLE 5 Formulation of Blackening Solution Component Formula Weight (g)Sodium Nitrate NaNO₃ 15 Sodium Hydroxide NaOH 35 Water H₂O 75 Cobalt(II)Nitrate Hexahydrate CoNO₃•6H₂O 1 Sodium Sulfide Nonahydrate Na₂S•9H₂O 3

A quantity of thirty (30) 22 mil type 4310 SH needles (manufactured byEthicon, Inc.) was immersed in a bath containing the activating solutionlisted in Table 1 at 80° C. for 2 minutes, and removed and rinsed withwater. The needles were then immersed in a bath containing theblackening solution listed in Table 5 at 100° C. for 1 minute. Theneedles were removed from the bath and it was observed that the surfacesof the needles turned black.

EXAMPLE 4 Formation of Manganese Oxide Containing an Iron Oxide BlackLayer

A small amount of potassium permanganate and Sodium thiocyanate wasadded to an alkaline solution of sodium nitrate as listed in Table 2 toform a blackening solution. The formulation of this blackening solutionis listed in Table 6

TABLE 6 Formulation of Example 5 Blackening Solution. Component FormulaWeight (g) Sodium Nitrate NaNO₃ 15 Sodium Hydroxide NaOH 35 Water H₂O 75Potassium Permanganate KMnO₄ 0.25 Sodium Thiocyanate NaSCN 0.25

A quantity of twenty (20) 22 mil type 4310 SH needles (manufactured byEthicon, Inc.) was immersed in a bath containing the activating solutionlisted in Table 1 at 80° C. for 2 minutes, and then rinsed with water.The needles were then immersed in a bath containing the blackeningsolution listed in Table 6 at 100° C. for one (1) minute after whichthey were removed from the bath. The silver needles turned intoblackened needles. It was observed that the surfaces of the silverneedles were completely blackened.

A larger batch trial was also conducted using bath solution volumes 8times the scale of activation and blackening solutions (1kg) for a batchof 750 of 24 mil type 4310 MH needles (manufactured by Ethicon, Inc.) ina similar manner with slight variations in the treatment time for eachof the steps. This large batch of needles was placed in the rotationalbasket (See FIGS. 1 and 2) and dipped in a bath containing theactivating solution at 80° C. for 2 minutes, removed and rinsed withwater, and then immersed in a bath containing the blackening solution at100° C. for 2 minutes. The needles were removed from the bath and it wasobserved that the surfaces of all of the silver needles in the batchwere completely blackened.

EXAMPLE 5 Formation of Manganese Oxide-Containing Iron Oxide Black Layeron the Surface of Surgical Needles Made From 4310 Alloy: Repeat Usage ofthe Blackening Solution

Example 5 is similar to Example 4, with the addition of 0.1 g sodiumchloride to the blackening solution. This enabled a faster blackeningreaction and along with repeat usage of the blackening solution. Theformulation of this blackening solution is contained in Table 7

TABLE 7 Formulation of Example 6 Blackening Solution. Component FormulaWeight (g) Sodium Nitrate NaNO₃ 15 Sodium Hydroxide NaOH 35 Water H₂O 75Potassium Permanganate KMnO₄ 0.25 Sodium Thiocyanate NaSCN 0.25 SodiumChloride NaCl 0.1

A batch of fifty (50) 22 mil type 4310 SH needles (manufactured byEthicon, Inc.) was immersed in a bath containing the activating solutionlisted in Table 1 at 80° C. for 30 seconds, then removed and rinsed withwater. The needles were then immersed in a bath containing theblackening solution listed in Table 7 at 100° C. for 10 seconds. Theneedles were removed from the bath and it was observed that the surfacesof all of the silver needles in the batch were completely blackened.

A larger batch trial was also conducted using bath solution volumes 8times the scale activation and blackening solutions (1 kg scale) for abatch of 750 24 mil type 4310 MH needles (manufactured by Ethicon, Inc.)in a similar manner with a slight variation of treatment times for eachof the steps. This large batch of needles was placed in the rotationalbasket (FIGS. 1 and 2) and dipped in the bath containing the activatingsolution at 80° C. for 2 minutes, removed and rinsed with water, andthen immersed in a bath containing the blackening solution at 100° C.for 2 minutes. The needles were removed from the bath and it wasobserved that the surfaces of all of the silver needles in the batchwere completely blackened.

The capability of the blackening solution to be used for additionalblackening cycles was also investigated and tested. It was observed thatby adding additional amounts of sodium thiocyanate and potassiumpermanganate as needed to maintain the blackening solution to theformulation of Table 7, the blackening solution could be repeatedlyre-used to effectively blacken batches of 750 24 mil MH needles, usingthe same activation and blackening parameters. It was observed that theblackening solution in the bath could be reused for at least 10 timeswith the blackened color of the surfaces of the needles remainingconsistent after each usage of the blackening solution.

The MH needles of Example 5 were submitted for Auger ElectronSpectroscopy analysis (Instrument model: PHI 680 Scanning AugerMicroprobe), in order to measure the composition and thickness of thesurface coating on this needle. A sputter depth profile revealed anoxide layer thickness of ˜1,500 Å, as illustrated in FIG. 5. Manganesewas the primary oxide in the outer ˜750 Å of the surface and then agradual increase in iron concentration was observed.

EXAMPLE 6 Formation of Silicone Coated Needles Made From the Large BatchProduction Described in Example 5

The entire batch of blackened 22 mil SH and 24 mil type 4310 MH needlesfrom Example 5 was immersed in a silicone solution consisting of 50 g ofNusil MED 4162 and 450 g of heptane, prior to placing them onconventional craft paper and dried in a fume hood at ambient conditionfor 30 minutes. The silicone coated blackened needles were then cured ina conventional oven at 160° C. for one hour. A batch of regular (thesilver needle) 22 mil type 4310 SH and 24 mil MH needles were alsoprepared in the same manor and used as control samples for the testing.

Coating performance for medical devices coated with silicone coatingcompositions can be tested with a variety of conventional friction oradhesion tests. In the case of surgical needles, coating performance,durability and integrity are evaluated using a conventional needlepenetration testing device. A coated surgical needle is held usingself-locking tweezers or a similar holding device. The coated needle isthen passed through a polymeric medium that is selected to berepresentative of general human tissue. Approximately half of the needlelength is passed through the medium and then retracted prior to the nextpass. The test media may be a type of synthetic rubber (e.g., Duraflex™,Manufacture by Monmouth Rubber and Plastic Corporation, Monmouth, N.J.).A typical test includes using multiple needles that are individuallypassed through the media 20 times each. The maximum force is recordedfor each pass and used as a measure of the coating performance.Typically the penetration force increases with each successive pass asthe coating wears off from the needle. Further detail of the equipmentand method can also be found in U.S. Pat. No. 5,181,416, which isincorporated by reference. ASTM F3014 is one example for a curved needlepenetration test protocol.

Penetration testing was performed on these two sets of curved needles.The results obtained were from penetration testing done using samples of30 individual needles. The average penetration force for each pass issummarized in Tables 8 and 9. The control samples for both sets ofneedles were also tested for the purpose of comparison, and the resultsare also included in these two tables.

TABLE 8 Needle Penetration Test: Example 6, 22 mil 4310 SH Avg. Avg.Stdv Avg. Stdv Force (g) Stdv Force(g) 10^(th) Force(g) 20th 1^(st) Pass1^(st) Pass 10^(th) Pass Pass 20^(th) Pass Pass Example 6 123 14.2 15112.2 174 13.8 Control 104 13.9 149 10.1 168 12.5 (4310 SH needles)

TABLE 9 Needle Penetration Test: Example 6, 24 mil 4310 MH Avg. Avg.Stdv Avg. Stdv Force (g) Stdv Force(g) 10^(th) Force(g) 20th 1^(st) Pass1^(st) Pass 10^(th) Pass Pass 20^(th) Pass Pass Example 6 121 14.1 18014.0 231 16.1 Control 108 12.7 180 11.2 218 12.0 (4310 MH needles)

Minor differences were found in the needle penetration results betweenboth codes of 4310 blackened needles of Example 6 and the controlsamples. Such differences are within the error of measurement method(10% approx.). The blackening process illustrated in Example 6 did notcreate a negative impact on the penetration performance of the resultingblackened, curved needles.

Bending stiffness of the coated 22 mil type 4310 blackened SH needleswas assessed according to ASTM F1874 on a set of 10 needles, against thecontrol sample coated 22 mil regular shiny silver 4310 SH needles, andthe results are summarized in Table 10.

As expected, the surface treatment to change the color of the needlesdid not have any significant impact on the stiffness and surgical yieldof the needles. There was also no significant difference in the reshapevalues indicating that the blackening process had no effect on the bulkproperty of the alloy and did not sensitize the surface to crackformation. Most importantly, the blackened needles did not have adifferent “feel” or behavior to the user.

TABLE 10 Ethicon Bend Test Results (Average Values for 10 Needles).Blackened 22 Current silver 22 mil SH needles mil SH needles fromExample 6 Reshape (number of bends  2.6 (stdv = 0.4)  2.9 (stdv = 0.2)before failure) YM (gf*cm) (Surgical Yield) 305.4 (stdv = 24.3) 310.4(stdv = 17.4) Stiffness (Elastic Modulus) 20.2 (stdv = 0.4) 20.0 (stdv =0.4)

EXAMPLE 7 Formation of Manganese Oxide-Containing Iron Oxide Black Layeron the Surface of Surgical Needles Made From Type 420 SS Alloy

The blackening solution used in Example 5 (Table 8) was used for thesample preparation. A quantity of twenty (20) 24 mi1 420 SH needles(manufactured by Ethicon, Inc.) was immersed in a bath containing theactivating solution listed in Table 1 at 80° C. for 30 seconds. Theneedles were then rinsed with water and immersed in a bath containingthe blackening solution listed in Table 7 at 100° C. for 30 seconds. Theneedles were removed from the bath and it was observed that the surfacesof all of the silver needles in the batch were completely blackened.

EXAMPLE 8 Formation of Manganese-Oxide Containing Iron Oxide Black Layeron the Surface of Surgical Needles Made From ETHALLOY Alloy

The blackening solution used in Example 5 (Table 7) was used for thesample preparation in this Example 8A and 8B.

8A-Loose ETHALLOY Needles for Batch Coating Trial With Nusil MED 4162Silicone

A quantity or batch of thirty (30) 24 mil ETHALLOY SH needles(manufactured by Ethicon, Inc.), cut out from a manufacturing processstrip into loose needles was immersed in a bath containing theactivating solution of Table 1 at 80° C. for 30 seconds, then removedand rinsed with water, and then immersed in a bath containing theblackening solution outlined in Table 7 at 100° C. for 30 seconds. Theneedles were removed from the bath and it was observed that the surfacesof all of the silver needles in the batch were blackened

8B-Strip With Mounted ETHALLOY Needles for Strip Coating Trial WithGelest XG-2385 Silicone

A strip having a quantity of ten (10) 24 mil ETHALLOY SH needles(manufactured by Ethicon, Inc.) mounted thereto was immersed in a bathcontaining the activating solution outlined in Table 1 at 80° C. for 30seconds, then rinsed with water, and then immersed in a bath containingthe blackening solution of Table 7 at 100° C. for 30 seconds. Theneedles were removed from the bath and it was observed that the surfacesof all of the silver needles in the batch were completely blackened.

8C-Large Batch of Loose ETHALLOY Needles for Batch Coating Trial,Multiple Usage Cycles of Blackening Bath

In order to address the color uniformity of ETHALLOY needles and therepeat usage of the blackening solution through successive cycles, anadditional component, ammonium molybdate tetrahydrate was added into thebase formulation of Table 7. The amount of the other additive, sodiumchloride, was also increased. The formulation of this blackeningsolution is contained in Table 11.

TABLE 11 Formulation of Example 9C Blackening Solution. ComponentFormula Weight (g) Sodium Nitrate NaNO₃ 120 Sodium Hydroxide NaOH 280Water 4H₂O 600 Potassium Permanganate KMnO₄ 3 Sodium Thiocyanate NaSCN 3Sodium Chloride NaCl 3 Ammonium Molybdate tetrahydrate (NH₄)₆Mo₇O₂₄•4H₂O3

A batch of eight hundred sixty (860) 26 mil V-7 needles (manufactured byEthicon, Inc.) was immersed in a bath containing the activating solutionlisted in Table 1 at 80° C. for 3 minutes, then removed and rinsed withwater. The needles were then immersed in a bath containing theblackening solution listed in Table 11 at 100° C. for 1 hour. Theneedles were removed from the bath and it was observed that the surfacesof all of the silver needles in the batch were completely blackened.

The capability of the blackening solution to be used for additionalblackening cycles was also investigated and tested. It was observed thatby adding additional amounts of sodium thiocyanate and potassiumpermanganate as needed to maintain the blackening solution to conform tothe formulation of Table 7, the blackening solution could be repeatedlyre-used to effectively blacken batches of 860 26 mil V-7 needles, usingthe same activation and blackening parameters. It was observed that theblackening solution in the bath could be reused for at least 3 timeswith the blackened color of the surfaces of the needles remainingconsistent after each usage of the blackening solution. It is believedthat that blackening solution could be reused a significantly largernumber of times by the addition of active components repeatedly asrequired to maintain the formulation.

EXAMPLE 9 Batch Coat Needles of Example 8A

This example is directed to the formation of silicone coated Ethalloy SHneedles made from the batch production highlighted in Example 8A, usinga batch coating process similar to the one used in conventionalChromium-based blackened needle production. The entire batch ofblackened 24 mil SH needles was immersed in a coating solutionconsisting of 50 g of Nusil MED 4162 and 450 g of heptane, prior toplacing the needles on a craft paper substrate and then drying in a fumehood at ambient conditions for 30 minutes. The silicone coated blackenedneedles were then cured at 160° C. for one hour in a conventionalconvection oven.

Penetration testing was then performed, as described above, on arepresentative sample of the coated needles. The results are frompenetration testing done using a sample of 10 individual needles. Thecoated needles were penetrated 20 times each. The average penetrationforce for each pass is summarized in Table 12.

TABLE 12 Needle Penetration Test: 24 mil Ethalloy SH, Batch Flow Avg.Avg. Stdv Avg. Stdv Force (g) Stdv Force(g) 10^(th) Force(g) 20thNeedles 1^(st) Pass 1^(st) Pass 10^(th) Pass Pass 20^(th) Pass PassExample 10 111 17.5 183 22.5 221 11.5

EXAMPLE 10 Strip Coating Needles of Example 8B

This example is directed to the formation of silicone coated Ethalloy SHneedles made from the strip process highlighted in Example 8B, using astrip coating process, in which all of the needles were mounted onto ametal strip and passed the coating solution in a dip tank in acontinuous manner. The strip of blackened 24 mil SH needles was immersedin a bath containing a silicone coating solution consisting of 23.8 g ofGelest XG-2385A, 23.8 g Gelest XG-2385B and 52.4 g of Isopar K. Thestrip with the needles was removed from the bath and placed in aconventional oven at 195° C. for 30 seconds. The silicone coatedblackened needles were further cured at 195° C. for 2 hours in aconventional convection oven.

Penetration testing was performed, as previously described, on theneedles having cured silicone coatings. The results were frompenetration testing done using a representative sample of 10 individualneedles that were removed from the strip. The coated needles werepenetrated 20 times each. The average penetration force for each passlisted in Table 13. The testing was conducted as described above.

TABLE 13 Needle Penetration Test: 24 mil Ethalloy SH, Strip Flow (Needlecode 362409) Avg. Avg. Stdv Avg. Stdv Force (g) Stdv Force(g) 10^(th)Force(g) 20th Needles 1^(st) Pass 1^(st) Pass 10^(th) Pass Pass 20^(th)Pass Pass Example 11 57 2.3 82 14.7 95 19.5

A 57% reduction was observed on the 20^(th) pass penetration of thestrip coated Ethalloy black SH needles (Example 10), compared to thesame lot of needles coated with Nusil MED6162 using a batch process. Theshort reaction time enables the conversion of the needle blackeningprocess to a strip flow and the usage of platinum cured silicone GelestXG-2385 (Manufacture by Gelest, Inc., Morrisville, Pa.). Significantimprovement on penetration performance can be achieved on blackenedneedles as demonstrated in this example.

EXAMPLE 11 Comparative Example—Blackening Bath of Example 6 WithoutNaNO3

This example is directed to the formation of dark green manganesecontaining iron oxide black layer on the surface of surgical needlesmade from Type 4310 SS alloy, instead of the black oxide layerdemonstrated in Example 6. The formulation of this blackening solutionis listed in Table 14.

TABLE 14 Formulation of Comparative Example 1 Solution. ComponentFormula Weight (g) Sodium Hydroxide NaOH 280 Water H₂O 720 PotassiumPermanganate KMnO₄ 3 Sodium thiocyanate NaSCN 3 Sodium chloride NaCl 3

A quantity or batch of 750, 26 mil MH needles (manufactured by Ethicon,Inc.) was immersed in a bath containing the activating solution of Table1 at 80° C. for 3 minutes, then rinsed with water, and then immersed ina bath containing the blackening solution listed in Table 14 at 100° C.for 2 minutes. After removal from the bath, the silver needles wereobserved to have a dark green appearance. Increasing the length of theprocess time in the bath solution did not change the color of theneedles. It was not possible to obtain truly black needles as a resultof treatment in the solution of this Table 14.

EXAMPLE 12 Comparative Example—Blackening Bath of Example 6 Without NaOH

This example did not lead to the formation of a black oxide black layeron the surfaces of surgical needles made from Type 4310 SS alloy incomparison to the black oxide layer demonstrated and obtained in Example5. The formulation of the blackening bath solution used in this exampleis listed in Table 15.

TABLE 15 Formulation of Comparative Example 1 Solution. ComponentFormula Weight (g) Sodium Hydroxide NaNO3 120 Water H₂O 880 PotassiumPermanganate KMnO₄ 3 Sodium thiocyanate NaSCN 3 Sodium chloride NaCl 3

A quantity or batch of 750, 26 mil MH needles (needle code MH002640Pmanufactured by Ethicon, Inc.) was immersed in a bath containing theactivating solution listed in Table 1 at 80° C. for 3 minutes, thenrinsed with water, and then immersed in a bath containing the solutionlisted in Table 15 at 100° C. for 2 minutes. After removal from thebath, the needle surfaces were observed to remain shiny and silver.Increasing the length of the process time in the blackening bathsolution did not change the color the needle. No blackened needles wereobtained as the result of the treatment in the solution of this example.

EXAMPLE 13 Comparative Example Inventive Process Versus Chromium(VI)-Based Process

A needle blackened by the process of the current invention as describedin Example 5 was compared with a needle treated by a prior art processusing chromium VI (EP1051538). The composition of the prior art processblackening bath is listed in Table 16.

TABLE 16 Formulation of Chromium VI Based Blackening Solution. ComponentFormula Weight (g) Sulfuric acid H2SO4 200 Chromium trioxide CrO3 200Water H₂O 600

A batch of 24 mil type 4310 MH needles similar to the needles blackenedby the process of Example 5 was pretreated in a similar manner andimmersed in a blackening bath solution having a composition as containedin Table 16. The needles were immersed in the coating bath of Table 16for 2 minutes, the same treatment time for the needles of Example 6treated with the process of the present invention. It was observed thatthe needles treated by the process of the present invention had all oftheir surfaces completely blackened. It was further observed the needlestreated with the prior art process remained shiny and silver color incolor, similar to the untreated 24mi1 type 4310 MH needles. Photographsof the needles are seen in FIGS. 3A and 3B.

FIG. 4 is a graph showing the difference in process time between theprocess of the present invention described in Example 5 and aconventional Chromium (VI)-based process. It can be seen that theprocess time of the present invention is significantly lower and moretime efficient than the Chromium (VI)-based process.

EXAMPLE 14 Needles Treated in Blackening Bath Without Pretreatment Bath

This example did not lead to the formation of a black oxide black layeron the surfaces of surgical needles made from Type 4310 SS alloy incomparison to the black oxide layer demonstrated and obtained inExample 1. The formulation of the blackening bath solution used in thisexample identical to the one used in Example 1 is listed in Table 3.

A quantity or batch of 750, 26 mil MH needles (manufactured by Ethicon,Inc.) was immersed in a bath containing the blackening solution listedin Table 3 at 100° C. for 2 minutes. The needles had not been subjectedto the pretreatment step. After removal from the bath, it was observedthat virtually no blackening occurred and the needle surfaces wereobserved to substantially remain shiny and silver. Increasing the lengthof the process time in the blackening bath solution to 10 minutes didnot change the color of the needles. No blackened needles were obtainedas a result of the treatment in the blackening solution of this example.

The novel blackening methods and blackening bath compositions of thepresent invention have many advantages. The advantages includesignificant reduction of process time, absence of toxic carcinogens,improved safety conditions, the elimination of hazardous waste, and theelimination of negative impacts on the environment.

Although this invention has been shown and described with respect todetailed embodiments thereof, it will be understood by those skilled inthe art that various changes in form and detail thereof may be madewithout departing from the spirit and scope of the claimed invention.

We claim:
 1. A method of blackening surgical needles, comprising thesteps of: A. placing at least one surgical needle having an outersurface into a pretreatment bath, wherein the pretreatment bathcomprises: about 10 wt. % to about 20 wt. % of water soluble chloridesalt; about 5% to about 15 wt. % of inorganic acid; about 65 wt. % toabout 80.% of water, wherein the pretreatment bath has a pH of about 0.5to about 1.2; and, B. then placing the surgical needle into a blackeningbath, wherein the bath comprises: about 3 wt. % to about 20 wt. % of ahighly soluble nitric acid salt; about 18 wt. % to about 38 wt. % of astrong base; about 50 wt. % to about 75 wt. % of water; about 0.2 wt. %to about 5 wt. % of a transition metal salt of a strong acid; about 0.2wt. % to about 5 wt. % of a sulfur-containing reducer compound; and, C.maintaining the needle in the blackening bath for a sufficientlyeffective period of time to provide a blackened coating on the outersurface of the needle.
 2. The method of claim 1, wherein the transitionmetal salt is selected from the group consisting of nickel nitrate,cobalt nitrate, nickel sulfate, cobalt sulfate, iron nitrate, copperperchlorate, nickel perchlorate, ion perchlorate, and cobaltperchlorate.
 3. The method of claim 1, wherein the sulfur-containingreducer is selected from the group consisting of N′-diethylthiourea,sodium thiocyanate, sodium sulfide, and sodium dimethyldithiocarbamate.4. The method of claim 1, wherein the highly soluble nitric acid salt isselected from the group consisting of sodium nitrate, potassium nitrate,and lithium nitrate.
 5. The method of claim 1, wherein the water solublechloride salt in the pretreatment bath is selected from the groupconsisting of sodium chloride, potassium chloride, and lithium chloride.6. The method of claim 1, wherein the strong base is selected from thegroup consisting of sodium hydroxide, potassium hydroxide, and lithiumhydroxide.
 7. The method of claim 1, wherein the inorganic acid in thepretreatment bath is selected from the group consisting of phosphoricacid, hydrochloric acid, sulphuric acid, and nitric acid.
 8. A method ofblackening surgical needles, comprising the steps of: A. placing atleast one surgical needle having an outer surface into a pretreatmentbath, wherein the pretreatment bath comprises: about 10 wt. % to about20 wt. % of water soluble chloride salt; about 5% to about 15 wt. % ofinorganic acid; about 65 wt. % to about 80.% of water, wherein thepretreatment bath has a pH of about 0.5 to about 1.2; and, B. thenplacing the surgical needle into a blackening bath, wherein the bathcomprises: about 3 wt. % to about 20 wt. % of a highly soluble nitricacid salt; about 18 wt. % to about 38 wt. % of a strong base; about 50wt. % to about 75 wt. % of water; about 0.2 wt. % to about 5 wt. % of ahighly soluble permanganate salt; about 0.2 wt. % to about 5 wt. % of athiocyanate salt; and, C. maintaining the needle in the blackening bathfor a sufficiently effective period of time to provide a blackenedcoating on the outer surface of the needle.
 9. The method of claim 8,wherein the permanganate salt is selected from the group consisting ofpotassium permanganate, sodium permanganate, and lithium permanganate.10. The method of claim 8, wherein the blackening bath additionallycomprises a water soluble chloride salt.
 11. The method of claim 8,wherein the thiocyanate salt is selected from the group consisting ofsodium thiocyanate, potassium thiocyanate, and lithium thiocyanate. 12.The method of claim 8, wherein the highly soluble nitric acid salt isselected from the group consisting of sodium nitrate, potassium nitrate,and lithium nitrate.
 13. The method of claim 8, wherein the strong baseis selected from the group consisting of sodium hydroxide, potassiumhydroxide, and lithium hydroxide.
 14. The method of claim 8, wherein theblackening bath additionally comprises about 0.2 wt. % to about 5 wt. %of a molybdate salt.
 15. A blackening bath composition for surgicalneedles, comprising: about 3 wt. % to about 20 wt. % of a highly solublenitric acid salt; about 18 wt. % to about 38 wt. % of a strong base;about 50 wt. % to about 75 wt. % of water; about 0.2 wt. % to about 5wt. % of a transition metal salt of a strong acid; and, about 0.2 wt. %to about 5 wt. % of a sulfur-containing reducer compound.
 16. Thecomposition of claim 15, wherein the transition metal salt is selectedfrom the group consisting of nickel nitrate, cobalt nitrate, nickelsulfate, cobalt sulfate, iron nitrate, copper perchlorate, nickelperchlorate, ion perchlorate, and cobalt perchlorate.
 17. The method ofclaim 15, wherein the sulfur-containing reducer is selected from thegroup consisting of, N′-diethylthiourea, sodium thiocyanate, sodiumsulfide, and sodium dimethyldithiocarbamate.
 18. The method of claim 15,wherein the highly soluble nitric acid salt is selected from the groupconsisting of sodium nitrate, potassium nitrate, and lithium nitrate.19. The composition of claim 15, wherein the strong base is selectedfrom the group consisting of sodium hydroxide, potassium hydroxide, andlithium hydroxide.
 20. A blackening bath composition for surgicalneedles, comprising: about 3 wt. % to about 20 wt. % of a highly solublenitric acid salt; about 18 wt. % to about 38 wt. % of a strong base;about 50 wt. % to about 75 wt. % of water; about 0.2 wt. % to about 5wt. % of a highly soluble permanganate salt; and, about 0.2 wt. % toabout 5 wt. % of a thiocyanate salt.
 21. The composition of claim 20,wherein the blackening bath additionally comprises a water solublechloride salt.
 22. The composition of claim 20, wherein the thiocyanatesalt is selected from the group consisting of sodium thiocyanate,potassium thiocyanate, and lithium thiocyanate.
 23. The composition ofclaim 20, wherein the highly soluble nitric acid salt is selected fromthe group consisting of sodium nitrate, potassium nitrate, and lithiumnitrate.
 24. The composition of claim 20, wherein the strong base isselected from the group consisting of sodium hydroxide, potassiumhydroxide, and lithium hydroxide.
 25. The composition of claim 20,wherein the blackening bath additionally comprises about 0.2 wt. % toabout 5 wt. % of a molybdate salt.
 26. A system for blackening stainlesssteel alloy surgical needles, comprising: A. a pretreatment bath, thepretreatment bath comprising: about 8 wt. % to about 20 wt. % of a watersoluble chloride salt; about 5 wt. % to about 15 wt. % of an inorganicacid; and, about 60 wt. % to about 90 wt. % of water wherein thepretreatment bath has a pH of about 0.5 to about 1.2; and, B. ablackening bath, the blackening bath comprising: about 3 wt. % to about15 wt. % of a highly soluble nitric acid salt; about 18 wt. % to about38 wt. % of a strong base; about 50 wt. % to about 75 wt. % of water;about 0.2 wt. % to about 5 wt. % of a transition metal salt of a strongacid; and. about 0.2 wt. % to about 5 wt. % of a sulfur-containingreducer compound.
 27. The system of claim 26, wherein the transitionmetal salt is selected from the group consisting of nickel nitrate,cobalt nitrate, nickel sulfate, cobalt sulfate, iron nitrate, copperperchlorate, nickel perchlorate, ion perchlorate, and cobaltperchlorate.
 28. The system of claim 26, wherein the sulfur-containingreducer is selected from the group consisting of N′-diethylthiourea,sodium thiocyanate, sodium sulfide, and sodium dimethyldithiocarbamate.29. The system of claim 26, wherein the highly soluble nitric acid saltis selected from the group consisting of sodium nitrate, potassiumnitrate, and lithium nitrate.
 30. The system of claim 26, wherein thewater soluble chloride salt is selected from the group consisting ofsodium chloride, potassium chloride, and lithium chloride.
 31. Thesystem of claim 26, wherein the strong base is selected from the groupconsisting of sodium hydroxide, potassium hydroxide, and lithiumhydroxide.
 32. The system of claim 26, wherein the inorganic acid isselected from the group consisting of phosphoric acid, sulphuric acid,hydrochloric acid, and nitric acid.
 33. A system for blackeningstainless steel alloy surgical needles, comprising: A. a pretreatmentbath, the pretreatment bath comprising: about 8 wt. % to about 20 wt. %of a water soluble chloride salt; about 5 wt. % to about 15 wt. % of aninorganic acid; and, about 60 wt. % to about 90 wt. % of water whereinthe pretreatment bath has a pH of about 0.5 to about 1.2; and, B. ablackening bath, the blackening bath comprising: about 3 wt. % to about20 wt. % of a highly soluble nitric acid salt; about 18 wt. % to about38 wt. % of a strong base; about 50 wt. % to about 75 wt. % of water;about 0.2 wt. % to about 5 wt. % of a highly soluble permanganate salt;and, about 0.2 wt. % to about 5 wt. % of a thiocyanate salt.
 34. Thesystem of claim 33, wherein the permanganate salt is selected from thegroup consisting of potassium permanganate, sodium permanganate, andlithium permanganate.
 35. The system of claim 33, wherein the blackeningbath additionally comprises a water soluble chloride salt.
 36. Thesystem of claim 33, wherein the thiocyanate salt is selected from thegroup consisting of sodium thiocyanate, potassium thiocyanate, andlithium thiocyanate.
 37. The system of claim 33, wherein the highlysoluble nitric acid salt is selected from the group consisting of sodiumnitrate, potassium nitrate, and lithium nitrate.
 38. The system of claim33, wherein the strong base is selected from the group consisting ofsodium hydroxide, potassium hydroxide, and lithium hydroxide.
 39. Thesystem of claim 33, wherein the blackening bath additionally comprisesabout 0.2 wt. % to about 5 wt. % of a molybdate salt.